Design and Installation Guide

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SLAB
Houses, Low
Rise MultiResidential and
Commercial
Floors
Design and
Installation
Guide
This Design Guide has been
prepared as a source of
information to provide general
guidance to consultants – and in
no way replaces the services of
the professional consultant and
relevant engineers designing the
project.
It is the responsibility of the
architectural designer and
engineering parties to ensure
that the details in this Design and
Installation Guide are appropriate
for the intended application.
The recommendations of this
guide are formulated along the
lines of good building practice,
but are not intended to be an
exhaustive statement of all
relevant data.
Contents
Introduction3
1 Design and selection details
6
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How to use this design and Installation Guide
6
System components
8
Design considerations
10 Architectural Specification
11 2 System performance
14 – System properties
14 – Building regulations
16 3 Installation detail
18 –TECSLAB™ installation sequence
18 – Construction details
19
™
–TECSLAB panel fixing details
22 – Control joint details
24 – Construction details
25 – Multi-Level Construction details
27 – Hold-down/bracing wall details
28 – Penetrations & notching details
29 – Wet area detail
29 – Balcony & staircase details
30 – Floor covering installation
31 – Tile installation
32 – Timber installation
33 4 Handling, storage and responsibility 34 –
–
–
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Delivery and storage
34 Tools and equipment for construction
35 Panel installation
36 Panel handling
37 Appendices38
– Appendix A. Hebel® PowerFloor™
panel material properties
– Appendix B. Estimating Hebel® PowerFloor™
– Appendix C. PowerFloor system description
2
38 39 42
The affordable
Premium lightweight
timber framed floor
system that feels like
a concrete floor.
TECSLAB™ is designed for
low, medium and highdensity construction and
combines the properties of
two exceptional construction
products TECBEAM™ and Hebel®
PowerFloor™ to provide a
superior floor solution achieving
quicker build times and
significant cost savings.
Hebel® is a lightweight steel-reinforced Autoclaved
Aerated Concrete (AAC) that has been used in Europe
for over 70 years and here in Australia for over 20
years.
TECBEAM™ is a composite structural ‘I’-Beam which
has a continuous galvanized steel web and timber
flanges resulting in a lightweight beam with structural
properties closely resembling those of a steel beam
rather than a solid beam. TECBEAM™ is designed and
manufactured in Australia by licensed fabricators and
holds worldwide patents for its technology.
Introduction
SLAB
A high-performance lightweight
flooring system
TECSLAB™ is a high performance lightweight flooring
system which provides a superior floor solution, with
the qualities and feel of a concrete floor and the
rigidity of a steel frame, at a significantly reduced cost.
TECSLAB™ can be easily installed by on-site carpenters
and is unaffected by wet or changing weather during
installation. Unlike wet-pour concrete, TECSLAB™ is
installed without the need for curing or propping.
Supremely comfortable, solid
and low noise emitting
The TECSLAB™ system reduces foot-fall, airborne noise
between floors and eliminates squeaking that is often
a problem with other joist systems and particle board
flooring.
TECSLAB™ boasts superior thermal performance
(particularly for suspended floors) and assists in
achieving thermal ratings that reduce heating and
cooling costs.
Proven in the market and
Australian designed and made
All components of the TECSLAB™ system are 100%
manufactured in Australia. Hebel® is manufactured
by CSR Building Products Limited and TECBEAM™
is fabricated by licensed Australian fabricators. You
can depend and rely on the product quality, technical
expertise, warranty and continuity of stock supplies.
With TECSLAB™ you can trust that everything has
been proven and tested*. The components are being
continually improved with ongoing research and
development.
*Logan Project Services Pty Ltd
Structural Engineers
www.tecslab.com.au/tecbeam
3
TECSLAB™. Better to build with…
Lightweight yet
solid and tough.
The TECSLAB™ system is
comprised of composite joists
made from timber flanges
and galvanized steel webbed
TECBEAM™s, which are typically
spaced at 450 or 600 centres;
together with the Hebel®
PowerFloor™ – a 75mm thick, steel
reinforced building panel made
from AAC (Autoclaved Aerated
Concrete) supplied in a length
1800mm by 600mm wide with a
tongue and groove profile.
Faster construction period
TECSLAB™ is a timber frame solution and is faster to
construct than suspended concrete. No propping and
curing of concrete is required. Typical placement rates
of 70m2 per day can be achieved with follow on trades
starting after 24 hours.
The TECBEAM™s can be installed quickly due to their
bespoke, made to measure fabrication. On site installation
time is accelerated as minimal modifications to the product
need to be made in-situ.
A comforting thought for a
comfortable living environment
Hebel®’s unique AAC construction provides superior
insulation qualities for a masonry product. The unique
combination of thermal resistance along with thermal
mass, make building with Hebel® a smart choice for
meeting Australia’s stringent building regulations.
For unit and home owners, the thermal efficiencies of
Hebel® reduce the reliance on heating and cooling
appliances – the combined effects of using a heater less
in winter and fans or air conditioning less in summer and
warmer months can have a big impact on rising energy
costs.
Highly fire resistant for peace of mind and added security
Hebel® is non-combustible and renowned for its highly fire
resistant properties. The PowerFloor™ System achieves a
FRL (Fire Resistance Levels tested at CSIRO) from 60–90
minutes below (with relevant fire-rated CSR Gyprock
ceiling) and –/240/240 minutes from above.
A sound reason for
better acoustic qualities
TECSLAB™ answers the practical issue of sound transfer
between floors. Creaking timber is a thing of the past as
the tongue and groove solid concrete floor locks together
and is reinforced with the rigidity of the TECBEAM™.
TECSLAB™ provides superior airborne noise insulation
particularly good for foot fall noise when installed with
resilient mounts. With home theatres becoming standard
in many modern homes, you can enjoy your entertainment
without disturbing the rest of the family.
4
Introduction
Hebel® PowerFloor™ panel
TECBEAM™ joist
Strongback
Wedges
Sustainability for a better world
in the long term starts today
TECBEAM™ achieves long spans and point load
carrying capacity whilst using far less steel than
standard structural steel bearers and joists. TECBEAM™
joists contain less that 15% of the embodied energy
of the steel beams they replace, without reducing
structural performance. TECBEAM™ provides an ideal
sub-structure for Hebel® due to its stiffness and low
long-term creep and deflection properties.
Hebel® delivers a diverse number of environmental
benefits over particle board and concrete. In an
independent Life Cycle Assessment (the leading
methodology used to quantify the environmental
impacts of a product’s entire life) undertaken by
Good Environment Choice Australia, in accord with
international standard ISO 14 024, Hebel® was found
to have clear environmental benefits across all key
environmental criteria.
To be awarded the label, products must have a 30%
lower impact than alternatives. Hebel® uses 64%
and 43% less greenhouse gas emissions than the
comparative products, concrete and particle board
flooring.
As environmental consciousness and social
responsibility increases, TECSLAB™ is striving to exceed
further to set new sustainability standards in building
materials and residential living.
...for all the
best reasons
With the attributes and benefits shown above this
innovative and versatile composite system provides
confidence that TECSLAB™ is an ideal solid floors
solution, as is detailed throughout the remainder of
this Design and Installation Guide.Less problems with
site access and disruption
Eliminates headaches of concrete truck queues and
pumps on site.
Better Environmental Choice
Environmental studies have demonstrated the
TECSLAB™ system replacing a suspended concrete slab
results in greater than 75% reduction in embodied
energy for an entire floor system. TECBEAM™ joists
contain less than 15% of the embodied energy* of the
steel beams they replace without reducing structural or
other environmental performance. Hebel® is certified by
Good Environmental Choice Australia.
*This study has been checked
and verified by environmental
consultants The Ark Climate Group.
www.arkclimate.com or
www.tecslab.com.au/sustainability
5
1. Design
Typical Applications
TECSLAB™ systems detailed in this design and installation guide are flooring solutions for residential, low rise
multi-residential, commercial* and industrial* construction. The floor applications consist of a Hebel® PowerFloor™ panel
connected to TECBEAMs™ forming a platform floor.
Figures 1.1, 1.2, 1.3 show typical applications for TECSLAB™ or more details refer to Hebel® Technical Update TU-009
and TECBEAM™ Installation Guidelines.
*For commercial and industrial applications, Hebel® floor surface may need temporary protection from high wear and tear during construction. 10mm ply is normally
sufficient. Please contact CSR Hebel® if more information is required.
Fig. 1.1 Residential – Suspended Ground
Floors
Fig 1.2 Residential – Suspended First
Floors
Fig 1.3 Commercial Floors – schools,
offices & community centres
1.2How to use this Design
and Installation Guide
Systems Index – Table 1.4
Architectural Specification
This allows the designer to quickly locate a system that
combines the acoustic rating (Rw), approximate floor
thickness (excluding TECBEAM™ height), floor covering
type and ceiling system requirement.
This material can be copied for inclusion onto working
drawings or project specifications. This provides a proforma layout with fill in sections to quickly and easily
create and customise project specifications.
System Components, System Properties & Design
Considerations
Installation Diagrams and Fixing Instructions
These sections provide relevant background information to
enable designers to plan and select appropriate TECSLAB™
systems.
TECSLAB™ System Pages
These pages provide detailed performance information to
assist in the selection of an appropriate TECSLAB™ system
for the application under consideration.
6
General design and installation information is provided
for the various systems available. For more detailed
information contact your CSR Hebel® representative. For
further information on different TECBEAM™ types and
their applications, please contact the TECBEAM™ joist
manufacturer.
Design and selection details
Selecting a system
STEP 1. Scan the ‘System Index’ for systems with the appropriate floor covering
for the intended application.
STEP 2. Turn to the selected system page and select ceiling system that provides appropriate
performance
(FRL/Rw/R-Value).
STEP 3. Consult your chosen structural engineer to determine a joist size and
spacing requirement.
STEP 4. Confirm structural adequacy. Contact the TECBEAM™ joist manufacturer,
or your chosen structural engineer.
STEP 5. Confirm acoustic and thermal performance by contacting the appropriate
project engineer.
Table 1.4 System index for CSR Hebel® PowerFloor™ Systems
Hebel® PowerFloor™
System Description
Floor
Covering Type
• Carpet
• Medium duty underlay
• 19mm T&G hardwood flooring
• 70 x 35mm timber battens
• 8mm Ceramic tiles
• Flexible adhesive
• Concrete topping slab
• Waterproof membrane
Applications
& Benefits
System No.
System Details
Page No.
• Carpeted floor with a high
level thermal performance.
TECSLAB™ 1600-1604
19
• Attractive solid timber finish
with a high level of thermal
performance.
TECSLAB™ 1620-1629
20
• Wet area applications where
a finished level has to be
built-up and/or a surface fall
is required.
TECSLAB™ 1610-1614
21
Note: Resilient mounts will help reduce footfall noise when using hard surface coverings such as tiles.
7
1.3 System Components
These components are compatible
with TECBEAM™ joists.
• Hebel® PowerFloor™ Panel
• Floor Covering
• Proprietary Ceiling System
• Hebel Adhesive
®
• Fuller® Max Bond™
• Fasteners & Fixings
Hebel® PowerFloor™ Panel
The Hebel® PowerFloor™ panel is available in a stock
length of 1800mm x 600mm width, with a mass of up to
56kg/panel. Where necessary, panels can be cut on-site
using a circular saw with diamond tipped cutting blade.
The minimum recommended width of a cut panel is
270mm width and 900mm in length.
The panels are screw fixed and bonded to all floor joists
except at panel butt joints. At butt joints, panels are
fixed using two beads of adhesive, and the screws may
be omitted. For further information on fixing Hebel®
PowerFloor™ panels, please refer to relevant construction
details outlined in this guide.
• Caulking
CSR Building Products Limited, guarantees
only the products that are manufactured by
CSR Hebel®, not the components, products or
services supplied by others.
Ceiling System Description
600mm
75mm
Fig 1.5 Hebel® PowerFloor™ Panel Cross Section
Ceiling System Components
a) CSR821
• CSR Resilient Mounts (No. CSR1) screw fixed to every joist at 600mm maximum centres.
• RONDO Furring Channel (No. 129) at 600mm maximum centres, clipped into resilient mounts.
• Bradford Glasswool Gold Batts R2.0 insulation infill.
• 1 layer x 13mm GYPROCK Plasterboard CD fixed to furring channel.
b) CSR 826
• CSR Resilient Mounts screw fixed to every joist at 600mm centres.
• RONDO Furring Channel (No. 129) at 600mm maximum centres, clipped into resilient mounts.
• 105mm Bradford Gold Insulation R2.0 GW insulation batts.
• 1 layer x 16mm GYPROCK FYRCHEK Plasterboard CD fixed to furring channel.
c) CSR 827
• CSR Resilient Mounts screw fixed to every joist at 600mm centres.
• RONDO Furring Channel (No. 129) at 600mm maximum centres, clipped into resilient mounts.
• Bradford Glasswool Gold Batts R2.0 insulation infill.
• 2 layers x 16mm GYPROCK FYRCHEK Plasterboard CD fixed to furring channel.
8
A range of floor coverings can be installed over the
Hebel® PowerFloor™ panels, such as, direct stick tiles,
carpet and underlay, topping slab and tiles and timber
(floating or on battens).
Proprietary Ceiling Systems
The underside of Hebel® PowerFloor™ can be lined
with proprietary ceiling systems. These ceiling systems
consist of combinations of components, such as
furring channel, resilient mounts, clips, suspended steel
framing, insulation, and plasterboard.
The most common combinations are detailed in the
table on the opposite page.
Design and selection details
Floor Coverings
Where panel ends butt together over a common joist,
two beads of adhesive shall be applied. Ensure the
surface is free of coatings and loose material that may
inhibit bond.
Fasteners
The correct sized fasteners for the construction of the
floor systems must always be used. Install screws as
shown in the Hebel® PowerFloor™ Panel Fixing Details
section of this guide.
Screws for fixing Hebel® PowerFloor™ panels
to TECBEAMs™ Joists: 14-10 x 100mm MP Bugle
Head Batten Screws or equivalent.
Further information on floor/ceiling systems is available
through CSR Gyprock, or the publications, CSR Gyprock
Fibre Cement Fire & Acoustic Design Guide (‘The
Red Book™’), NºGYP500, and CSR Gyprock Ceiling
Systems Installation Guide, NºGYP570 and TECBEAM™
Installation Guidelines.
Timber & Steel Support Systems
Caulking
TECBEAM flooring can be used to support the Hebel
PowerFloor™ panels. The allowable spacing of the
joists is 450mm or 600mm only. The joists, bearers
and other supports shall be sized in accordance with
the framing manufacturer’s recommendations. Where
steel joist framing is used it must be ensured that the
PowerFloor panels are provided with uniform and
complete bearing onto each steel joist.
Hebel® PowerFloor™ requires that all gaps at
openings, penetrations and control joints be caulked
to provide an airtight floor system that maintains
acoustic, thermal,vermin and fire resistance
performance. All gaps must be carefully and completely
filled with an appropriate flexible polyurethane sealant,
installed in accordance with the sealant manufacturer’s
specifications.
Note: The designer should allow at least 51kg/m2 for the
selfweight of the Hebel® PowerFloor™ panel. A minimum
joist flange width of 45mm is required.
Hebel® Patch
™
®
Hebel Adhesive
®
Hebel® Adhesive (supplied in 20kg bags) is used for
gluing the panels together at all joints. Typically, panel
joints are 2-3mm thick. Sufficient pressure is to be
applied to the joint to ensure full coverage of adhesive
in the joint. Adhesive is to be mixed to the proportions
as stated on the bag.
Construction Adhesive
A 5mm (minimum) bead of Fuller Max Bond
construction adhesive is applied to the top of the joists.
Minor chips or damage to panels are to be repaired
using Hebel® Patch. Hebel® Patch is available in 10kg
bags.
Hebel® anticorrosion
protection paint
Reinforcement exposed when
panels are cut shall be coated
with a liberal application
of Hebel® anti-corrosion
protection paint.
9
1.4 Design Considerations
Acoustics
• Typically at a max. spacing of 6000mm.
Placement of insulation in the ceiling cavity can enhance
the sound insulation performance of a floor/ceiling system.
A carpet/underlay floor covering incorporated with
TECSLAB™ will provide the best impact sound resistance.
For hard surface floor coverings, we suggest using a
floating floor and/or an independent ceiling system,
incorporating resilient mounts or resilient furring channels.
• Over lines of support for the TECBEAM™ joists. Refer to
Fig 3.10.
For ceilings that incorporate resilient mounts or resilient
furring channels, flanking sound paths through adjacent
walls are common, especially in timber framed buildings.
To maintain Rw and IIC ratings, the wall linings may also
need to be resiliently mounted. For multi-tenancy buildings,
providing a control joint at the party wall will break a
flanking path and maintain acoustic amenity.
Alternative Framing
TECBEAM™ joists may be used without reducing the
system FRL rating for a fire source ‘from above’. The design
of joists shall allow for temperature effects. Alternative
support framing systems may affect acoustic performance,
and advice from an acoustic consultant is recommended.
Penetration Restrictions
Penetrations are required to accommodate services, such
as waste pipe-work, water pipe-work, and air conditioning
ductwork, etc. Hebel® PowerFloor™ can accommodate an
80mm maximum circular penetration without a reduction
in structural performance. Multiple penetrations in the
same panel are to be in a straight line, parallel to the long
edge of the panel.
For large or clustered multiple penetrations, additional joists
or bridging should be included for support of the panel
in this area. Refer to the ‘Penetration & Notching Details’
section of this guide. All penetrations are a potential source
for water ingress or air leaks, and should be sealed with an
appropriate flexible fire rated sealant or proprietary collar.
Control Joint Layout
Control joints are a necessary part of Hebel®
PowerFloor™. Control joints provide a region in which to
relieve stress due to movement of the structural system,
and to control the location where movement can occur
without a detrimental effect on the floor finish.
Recommended locations for control joints are:
10
• Located at lines of bracing, ensuring a diaphragm
between the bracing lines
• Located at changes in joist orientation.
Wet Area Floor Construction
All wet areas require a waterproof membrane layer
over the Hebel® PowerFloor™ panel. Waterproofing
membranes shall be nominated by the designer or
specifier, and installed in accordance with manufacturer’s
recommendations.
Serviceability Behaviour
The deflection limits of the floor are governed by the
adopted TECBEAM™ size. As a guide, the following typical
deflection limits provide acceptable behaviour and dynamic
response:
• Dead Load (DL): span/300 or 12.5mm max.
• Live Load (LL): span/360 or 9mm max.
• DL & LL: span/400.
• Dynamic Response: 2mm max. under a 1kN point load.
Concentrated Loads
For concentrated loadings, such as a loadbearing wall or
point loads, the designer should ensure additional joists or
blocking are provided beneath the wall or bearing plate.
This will reduce the localised bearing stress. Bearing stress
in the AAC shall be limited to 1.0MPa.
Note: The designer should select appropriate deflection
limits to suit individual projects.
Bracing Walls
For bracing walls parallel to TECBEAM™ joists, a joist
shall be positioned beneath the wall. For bracing walls
perpendicular to TECBEAM™, blocking shall be positioned
beneath the wall. Blocking shall have a minimum width
of 45mm. Bearing stress in the AAC shall be limited to
1.0MPa.
Panel Support
All Hebel® PowerFloor™ panels are to start and finish on a
TECBEAM™. Panels must be joined on a TECBEAM™.
This specification should be adopted as a guide only,
and shall be superseded by the contract specifications
of the project.
Please note * denotes areas to insert or select
appropriate specifications.
Scope
The contractor shall furnish all material and equipment
required to satisfactorily complete the installation and
jointing of TECSLAB™ where indicated in the contract
specification.
Materials
All AAC material shall be a Hebel® PowerFloor™ panel
as manufactured by CSR Hebel®.
All accompanying fixings shall be those supplied by
CSR Hebel®, TECBEAM™ fabricator or approved by the
project engineer.
All lining materials shall be Gyprock plasterboard
as manufactured and supplied by CSR Gyprock (or
products of equivalent or better performance). All
plasterboard shall be manufactured to meet the
dimensional requirements of AS/NZS2588 ‘Gypsum
Plasterboard’.
Construction adhesive shall be Fuller Max Bond as
manufactured and supplied by Fuller (or products of
equivalent or better performance).
All sealants shall be a polyurethane type with required
fire and acoustic ratings, (or products of equivalent or
better performance).
All infill materials shall be products manufactured and
supplied by CSR Bradford® (or products of equivalent or
better performance).
Design and selection details
1.5 Architectural Specification
Hebel® PowerFloor™ System
The contractor shall supply and install
a Hebel® PowerFloor™ system
*PF-………(…), in accordance with CSR
Hebel® Detached Houses & Low Rise Multi-Residential
Floor Design Guide, TECBEAM™ Installation Guide,
NºHBLA185, and CSR Gyprock Fibre Cement Fire &
Acoustic Design Guide (‘The Red Book™’), NºGYP500,
and shall satisfy the following performance criteria.
The TECSLAB™ system shall have a Fire Resistance
Level of *FRL…/…/… for a fire source ‘from above’ in
accordance with the requirements of AS1530.4. Design
of the joists shall allow for temperature effects.
Installation shall be carried out to the level specified for
a field acoustic performance of *Dntw………… using
cavity infill of *Bradford …………… (or products of
equivalent or better performance).
Levels of Finish – Floor Covering
Prior to installation of the floor covering, the contractor
shall ensure the installed panels are within the
tolerances of the project specifications. The contractor
shall ensure that all control joints are installed as
per project specifications, panel joints are completely
filled with Hebel® Adhesive, minor chipping damage
of the panels shall be patched with Hebel® Mortar,
and all sealants are installed as per manufacturer’s
specifications.
Floor coverings shall be installed as per manufacturer’s
specifications, unless specified otherwise in the contract
documentation.
Ceiling System
The contractor shall supply and install the Gyprock
Ceiling System *N°CSR……… in accordance with
CSR Gyprock Fibre Cement Fire & Acoustic Design
Guide (‘The Red Book ‘), NºGYP500. The ceiling
framing shall be lined with *……… layers of………
mm Gyprock……… plasterboard.
*Denotes areas to insert or select appropriate
specifications.
11
Please note * denotes areas to insert or select
appropriate specifications.
Levels of Finish – Ceiling Systems
All ceiling framing systems, plasterboard lining, jointing
and finishing shall be carried out to *Level ……… Level
of Finish, in accordance with CSR Gyprock Plasterboard
Residential Installation Guide, NºGYP547, AS/NZS2589.1
‘Gypsum Linings in Residential and Light Commercial
Construction - Application and Finishing’.
Plasterboard
The Hebel® PowerFloor™ system ceiling framing shall be
lined with *………… layer/s of …………mm Gyprock
……………… plasterboard.
Plasterboard fixing
All layers shall be fixed to the framing (ie., timber or steel
floor joists and/or steel furring channels) as specified for
the relevant system in the CSR Gyprock Ceiling Systems
Installation Guide, NºGYP570, other relevant CSR Gyprock
technical literature, and Rondo Building Services Pty Ltd
literature or steel frame manufacturer’s literature.
Jointing & Finishing
Jointing and finishing of the outer layer of plasterboard
shall be in accordance with the CSR Gyprock Plasterboard
Residential Installation Guide, NºGYP547.
12
Caulking
Where caulking is indicated in fire rated systems
*…………………… fire rated polyurethane sealant
or fire rated backing rod with *……………… acoustic
rated polyurethane sealant shall be used, and installed in
accordance with the manufacturer’s recommendations.
Where caulking is indicated in wet areas, a
*…………………… polyurethane sealant must
be used when caulking *non-fire rated/fire rated wet
areas, as indicated, and installed in accordance with the
manufacturer’s recommendations.
Important
Any variation or substitution of materials or assembly
requirements, or compromise in assembly may result in
failure under critical conditions.
Note: This information can be downloaded from the CSR
Hebel® website: www.hebelaustralia.com.au
*Denotes areas to insert or select appropriate specifications.
Design and selection details
Design notes:
13
2.1 System Properties
Structural Performance
Acoustic Considerations
TECSLAB™ systems can support a maximum uniformly
distributed load of 5kPa, or concentrated (point) load
of 1.8kN over a load area of 350mm2 (with joists at
450mm or 600mm centres only) 3.9kN over a load area of
10,000mm2. For loads outside this range, please contact
CSR Hebel® or your TECBEAM™ fabricator.
Sound Ratings
The designer should specify the magnitude of the gaps
between the Hebel® PowerFloor™ panel and structure. This
gap will allow movement to release any confining stresses
due to movement of the supporting structure.
Durability
Where TECSLAB™ is installed in a multi-residential/
commercial application, the PowerFloor panels must be
suitably protected against trafficability during construction
to maintain the long term durability and integrity of the
panels. It is the responsibility of the builder to provide
and maintain such protective coverings to the PowerFloor
panels until such time that the finished floor coverings are
installed.
For application of TECSLAB™ in commercial projects Hebel®
Technical Services must be contacted for advising on
durability and protection of the PowerFloor panels during
construction.
Fire Resistant Levels
Australian building regulations express the fire
performance of a floor/ceiling with the rating system called
the ‘Fire Resistance Level’ (FRL). The FRL rating of the
systems detailed in this guide are opinions issued by the
CSIRO based on test results.
Testing has been conducted in accordance with the
Australian Standard AS1530 : Part 4 ‘Fire Resistance Tests
of Elements of Building Construction’.
The FRL rating consists of three performance criteria,
structural adequacy/integrity/insulation. For example, the
FRL of a floor may be expressed as 180/120/90. Where
‘180’ indicates a rating for ‘structural adequacy’ of 180
minutes, followed by ‘integrity’ for 120 minutes, and
‘insulation’ for 90 minutes. The Hebel® PowerFloor™
system has fire resistance of 240 minutes from a fire
source above the floor. For fire resistance to a fire source
below the floor a fire rated ceiling system must be
installed.
14
Floor systems, consisting of the Hebel® PowerFloor™ and
other products, have been laboratory tested to establish
their sound insulation characteristics. A laboratory test
involves the installation of a system between two massive
concrete rooms, which are normally well isolated from one
another,
so that only direct transmission is via the system.
A steady sound level of various frequencies is generated
on one side and measurements taken on both sides. These
measurements are made in one/third octave bands from
100Hz to 5000Hz. For each specified frequency, the sound
transmission loss is calculated. To assist in communication
the performance is conveniently expressed as a single
number called the ‘Weighted Sound Reduction Index’ (Rw).
Weighted Sound Reduction Index (Rw)
Recently, Australian building regulations have adopted
the International Standard Organisation acoustic rating
system called the ‘Weighted Sound Reduction Index’ (Rw).
The Rw value replaces ‘Sound Transmission Class’ (STC)
as a measure of the acoustic performance of a wall. A
correction figure of Ctr is added to the Rw value to better
quantify the acoustic performance of the building system.
Ctr Adaptation Term
The normal rating of Rw more closely defines the acoustic
performance for speech frequencies. Where low frequency
sound insulation performance is important, as may be
the case with traffic noise or music and DVD systems,
then a correction factor is applied to the airborne sound
rating (Rw) to differentiate the systems with good sound
insulation to these frequencies. The factor is Ctr and it
is a negative value. A system with good low frequency
performance will have a value of say -4; a system with
poor performance will have a value of say -12.
Impact Isolation Class (IIC)
The ‘Impact Isolation Class’ (IIC) quantifies the transmission
of impact sound through a floor/ceiling system.
The test involves impacting the floor assembly with a
standard tapping machine and measuring the sound level
below in the same manner as described for the airborne
sound insulation. Higher numbers indicate less sound is
being transmitted. IIC is an American system and is now
being replaced by Ln,w, which is the ISO equivalent.
This is the measure of the weighted and adjusted
sound level below the floor when the tapping machine
is operated above. In this case the lower the value the
better the acoustic performance.
Thermal Performance
There is an approximate relationship between Ln,w
and IIC, either can be subtracted from the numerical
value of 110 to determine the other.
Thermal performance is concerned with the energy
retention or loss characteristics of a building system.
One of the primary design objectives in planning a cost
effective building is to provide a comfortable living/
working environment for the building’s inhabitants.
Exploiting the inherent thermal qualities of Hebel® AAC
enables the designer to achieve this objective.
C1 Adaptation Term
R-Value Rating
The rating by Ln,w appears to work well where carpets
or floating floors are employed on concrete or timber
framed floors. With hard floor finishes, particularly with
timber joist floors, the low frequency performance may
require further consideration by your acoustic consultant.
The energy demand can be minimised by controlling
the heat transfer, which is heat flowing from a hot
region to a colder region, through a building system.
The thermal resistance of a building system is
expressed as the R-Value. The R-Value of the system is
the sum of the R-Values of the individual components.
Test Reports
All test reports quoted in this guide have been issued
by the CSIRO, National Acoustic Laboratory or other
NATA Registered Laboratories. Testing has been
conducted in accordance with the relevant Australian
Standard at the time of testing.
Sound Transmission Estimates
Computer models are used to determine sound
transmission estimates for specific configurations, known
as ‘Acoustic Assessments’. The computer model predicts
the Rw performance expected from the laboratory test
on the system, with a 96% confidence limit of ±2.5 db.
System performance
Ln,w
Thermal Integrity
Poor thermal integrity, due to bad construction
practices can also significantly affect the comfort
performance, as poor sealing and gaps allow air to
infiltrate as drafts. The inherent construction tolerances
of Hebel® PowerFloor™ provides a floor with a low
infiltration rate and good thermal integrity.
Performance – Laboratory vs Field.
When selecting the appropriate TECSLAB™ system, the
designer or specifier must be aware that the laboratory
Rw values are always higher than the field measured
values (Rw). This is due to the field conditions, such as
flanking paths, air leaks, floor frame construction type
and stiffness, etc., which can be introduced by careless
building design or construction. To avoid significant
reductions in acoustic performance published
construction details must be followed completely.
Independent specific advice and confirmation should
be sought for specific projects where the presence of
flanking paths or any other acoustic effect may affect
field performance.
Typically, the field performance of a system will be 2
to 5 Rw units lower than the laboratory performance,
and allowance should be made for this by the acoustic
consultant during the selection of the floor system.
15
2.2 Building Regulations
Intertenancy Floors
Floors constructed between separate tenancies are
required to achieve a minimum acoustic and fire
performance.
Acoustic Performance
For Class 2 and 3 Building with floors separating sole
occupancies the following minimum acoustic requirements
are described in the BCA:
• Airborne Sound Transmission:
Rw + Ctr ≥ 50
•Impact Sound Transmission:
Ln,w + Cl ≤ 62
Or, measured in-situ performance of:
• Airborne Sound Transmission:
Dnt,w + Ctr ≥ 50
•Impact Sound Transmission:
Lnt,w + CI ≤ 62
Fire Performance
For Class 2 and 3 Building with floors separating sole
occupancies the following fire requirements are described
in the BCA:
•FRL - 90/90/90 (Structural Adequacy/ Integrity/
Insulation)
Please refer to section C of the BCA for certain exemptions
to the above fire rating requirements.
16
Compliance with the Building Code of Australia
(BCA)
All building solutions, such as walls, floors, ceilings, etc.
must comply with the regulations outlined in the BCA or
other authority.
The BCA is a performance based document, and is
available in two volumes which align with two groups
of ‘Class of Building’:
Volume 1: Class 2 to Class 9 Buildings; and
Volume 2: Class 1 & Class 10 Buildings – Housing
Provisions.
Each volume presents regulatory Performance
Requirements for different Building Solutions for various
classes of buildings and performance provisions.
These Performance Provisions include: Structure; Fire
Resistance; Damp & Weatherproofing; Sound Transmission
& Insulation; and Energy Efficiency.
This design guide presents tables, charts and information
necessary to design a Hebel® PowerWall™ that complies
with the Performance Requirements of the BCA. The
designer must check the adequacy of the building solution
for Performance Requirements outlined by the appropriate
authority.
Design and selection details
Design notes:
17
3.1 TECSLAB™ Installation Sequence
1.Preparation of Framing for Hebel®
PowerFloor™ Panel Installation
• Check floor framing is complete and within level tolerances.
• Provide set-out chalk lines, as required.
• Provide temporary installation platform where necessary.
• Ensure floor framing has adequate strength to support
Hebel® PowerFloor™ bundles.
• Position Hebel® PowerFloor™ bundles on the floor framing.
2.Hebel® PowerFloor™ Panel
Installation
• Panels are to be installed in a stretcher bond pattern, with a
minimum overlap of 1 joist space and not less than 450mm.
• Use lifting handles or trolley to move the panels to
installation area.
• Apply a 5mm min. bead of Fuller Max Bond construction
adhesive (or equivalent) to top of joists in accordance with
manufacturer’s instructions, and apply Hebel® Adhesive to
appropriate panel edges.
• Panels must be installed with minimal horizontal sliding
on the joists to ensure a good bond. Force the tongue
and groove joint closed as the panel is rolled and lowered
onto the joists. Ensure all joints are tight and that adhesive
makes full contact along all joints.
• Screw fix panel to the joists as required.
• Repeat process, removing excess Hebel® Adhesive.
3.Penetration Detailing
• Install blocking to support Hebel® PowerFloor™ panel at
major openings.
4.Floor Finishes
• Sweep the floor surface to remove debris and loose
particles.
• Fill joints and screw holes with Hebel® Adhesive, as
required.
• Ensure perimeter is not chipped.
•Install floor covering for Hebel® PowerFloor system in
accordance with manufacturer’s specifications.
Note: Ensure panel moisture content is within limits outlined by
the floor covering manufacturer.
18
Installation detail
3.2 Construction Details
TECSLAB™ System Carpet
Recommended for: Rigid, lightweight floor system with high impact sound insulation.
Carpet
Medium duty underlay
Screw fixing to suit TECBEAM™ joist
Hebel® PowerFloor™ panel
Hebel® Adhesive
Fuller® Max Bond™ construction adhesive
installed to manufacturer’s specifications
TECBEAM™ joist
TECBEAM™ joist
NOTE: Patching of recesses at fixings or localised chipping may be required prior to installation of floor coverings.
Carpet
Fire*
Acoustic
Thermal
R-value
up
R-value
down
45
1.60
1.72
30
45
1.01
1.06
55
48
35
3.20
3.50
60/60/60
56
49
34
3.17
3.56
90/90/90
58
52
32
3.31
3.61
Rw
Rw +
Ctr
Code
System Description
FRL
TECSLAB™ 1600
Houses, Low Rise and Commercial Floor Carpet Ground
Floor Enclosed
240 minutes*
33
30
TECSLAB™ 1601
Houses, Low Rise and Commercial Floor Carpet Ground
Floor Unenclosed
240 minutes*
33
TECSLAB™ 1602
Houses, Low Rise and Commercial Floor Carpet 2nd Storey
Gyprock Ceiling (CSR 821)
-/-/-
TECSLAB™ 1603
Houses, Low Rise and Commercial Floor Carpet 2nd Storey
Gyprock Ceiling (CSR 826)
TECSLAB™ 1604
Houses, Low Rise and Commercial Floor Carpet 2nd Storey
Gyprock Ceiling (CSR 827)
Lnw +
C1
Note *Fire source from above only.
Please refer to description on page 23 for all Acoustic, Thermal and Fire assessments.
19
TECSLAB™ System Timber Floors
Recommended for: Rigid, lightweight floor system with excellent thermal insulation and decorative timber flooring.
OPTION 1
Batten fixed timber
OPTION 2
Floating timber floor
PVC sheeting as required
Foam underlay
OPTION 3
Direct stick
Screw fixing to suit TECBEAM™ joist
Hebel® PowerFloor™ panel
Hebel® Adhesive
Fuller® Max Bond™ construction adhesive
installed to manufacturer’s specifications
Floor adhesive
TECBEAM™ joist
TECBEAM™ joist
NOTE: Patching of recesses at fixings or localised chipping may be required prior to installation of floor coverings.
Timber on
Battens
Fire*
Acoustic
Code
System Description
FRL
Rw
TECSLAB™ 1620
Houses, Low Rise and Commercial Floor Timber
Battens Ground Floor Enclosed
240 minutes*
37
TECSLAB™ 1621
Houses, Low Rise and Commercial Floor Timber
Battens Ground Floor Unenclosed
240 minutes*
TECSLAB™ 1622
Houses, Low Rise and Commercial Floor Timber
Battens 2nd Storey Gyprock Ceiling (CSR 821)
TECSLAB™ 1623
TECSLAB™ 1624
Rw+Ctr
R-value
down
Lnw + C1
R-value up
33
83
1.65
1.74
37
33
83
1.00
1.08
-/-/-
55
48
66
3.18
3.51
Houses, Low Rise and Commercial Floor Timber
Battens 2nd Storey Gyprock Ceiling (CSR 826)
60/60/60
56
48
66
3.17
3.57
Houses, Low Rise and Commercial Floor Timber
Battens 2nd Storey Gyprock Ceiling (CSR 827)
90/90/90
58
50
63
3.29
3.62
Note *Fire source from above only
Please refer to description on page 23 for all Acoustic, Thermal and Fire assessments.
20
Thermal
Installation detail
TECSLAB™ System 8mm Ceramic Tiles on 50mm Topping Slab
Recommended for: Rigid, lightweight floor system where a fall is required for drainage.
OPTION 1
With flexible adhesive
Tiles fixed with a flexible adhesive
Flexible adhesive
OPTION 2
Without flexible adhesive
Concrete topping slab
Waterproof membrane
Screw fixing to suit TECBEAM™ joist
Hebel® PowerFloor™ panel
Hebel® Adhesive
Fuller® Max Bond™ construction adhesive
installed to manufacturer’s specifications
TECBEAM™ joist
TECBEAM™ joist
NOTE: Patching of recesses at fixings or localised chipping may be required prior to installation of floor coverings.
8mm Ceramic Tiles on
50mm Topping Slab
Fire*
Acoustic
Thermal
Lnw + C1
R-value
up
R-value
down
33
72
1.42
1.49
37
33
72
0.77
0.82
-/-/-
56
49
57
2.97
3.26
Houses, Low Rise and Commercial Floor Tiles on
Topping Slab 2nd Storey Gyprock Ceiling (CSR 826)
60/60/60
57
50
56
2.94
3.32
Houses, Low Rise and Commercial Floor Tiles on
Topping Slab 2nd Storey Gyprock Ceiling (CSR 827)
90/90/90
59
53
54
3.08
3.37
Code
System Description
FRL
Rw
TECSLAB™ 1610
Houses, Low Rise and Commercial Floor Tiles on
Topping Slab Ground Floor Enclosed
240
minutes*
37
TECSLAB™ 1611
Houses, Low Rise and Commercial Floor Tiles on
Topping Slab Ground Floor Unenclosed
240
minutes*
TECSLAB™ 1612
Houses, Low Rise and Commercial Floor Tiles on
Topping Slab 2nd Storey Gyprock Ceiling (CSR 821)
TECSLAB™ 1613
TECSLAB™ 1614
Rw+Ctr
Description
Fire from above only – Opinion FCO 1303
Fire from below only – Opinion FCO 1373. (Refer to CSR Gyprock)
Combined floor and ceiling system thermal values are opinions determined for internal conditions above and internal
conditions below. Airflow direction – Up = Summer, Down = Winter
Acoustic Test CSIRO – TL413 – airborne sound transmission
Acoustic Test CSIRO – TLi413 – impact sound transmission
Acoustic Assessment PKA – 210 091 A071
Thermal calculation by James Fricker 107.23 to 107.29 August 2011. Thermal calculations for second floor have assumed
140mm deep joist sections.
For detailed information on ceiling systems, please refer to ‘System Components’ Section of this design guide and the CSR
Gyprock Fibre Cement Fire & Acoustic Design Guide (The Red Book™). For detailed information on acoustic
21
3.3 TECSLAB™ Panel Fixing Details
Fig 3.3.1 TECSLAB™ panel fixing details
Butt joint fixing, apply two beads of adhesive
and omit screws
Internal fixing, two screws at each TECBEAM™
joist at 100mm min. from panel edge
Minimum overlap one TECBEAM™ joist
spacing not less than 450mm
Tongue and groove joint
End screw fixing,
two screws in
every panel
100mm min.
from long edge
of panel
Two beads of
construction adhesive
at the ends of panels
All joints
(2–3mm width)
completely filled with
Hebel® Adhesive
TECBEAM™ joist at
600mm max. centres
TECBEAM™ joist
Ribbon plate
Wall frame
Continuous 5mm bead
of Fuller® Max Bond™
construction adhesive
installed to
manufacturer’s
specifications
Fig. 3.3.3 Fixing of Hebel® PowerFloor™
panel to TECBEAM™ joists
Fig. 3.3.4 Fixing at end of Hebel® PowerFloor™
panel to TECBEAM™ joists
14-10 x 100mm MP bugle head
batten screw
14-10 x 100mm MP bugle head
batten screw
Patch with Hebel® Adhesive flush
with panel surface
Patch with Hebel® Adhesive flush
with panel surface
Hebel® PowerFloor™ panel
Hebel® PowerFloor™ panel
Fuller® Max Bond™
construction adhesive
Fuller® Max Bond™
construction adhesive
TECBEAM™ joist
TECBEAM™ joist
22
Installation detail
Fig. 3.3.5 Fixing to TECBEAM™ joists at change in joist orientation
Control joint
50mm min.
14-10 x 100mm MP bugle head
batten screw
Patch with Hebel® adhesive flush
with panel surface
Hebel® PowerFloor™ panel
Hebel® PowerFloor™ panel
Fuller® Max Bond™
construction adhesive
TECBEAM™ joist
TECBEAM™ joist
90mm
Fig. 3.3.6 Cross-section of TECSLAB™ installation
100mm min. 100mm min.
Two 14-10 x 100mm MP bugle head batten
screws in each panel at every TECBEAM™
joist 100mm min. from edge. Screw fixing at
butt joint optional
Patch with Hebel® Adhesive flush with panel
150mm max. 150mm max. surface
100mm min. 100mm min.
150mm max. 150mm max.
Hebel® PowerFloor™ panel
Hebel® Adhesive
5mm min. diameter bead of Fuller®
Max Bond™ construction adhesive
between PowerFloor™ panel and
TECBEAM™ joists
TECBEAM™ joist
23
3.4 Control Joint Details
Fig. 3.4.1 Recommended Control Joint Location for
Eccentric Loadbearing Wall
Fig. 3.4.2 Recommended Control Joint Location for
change in TECBEAM™ joist orientation
LOAD
Loadbearing wall
Hebel® adhesive
Hebel® adhesive
Hebel® PowerFloor™ panel
Control Joint
30mm min.
Hebel® PowerFloor™ panel
Control Joint
Blocking
where required
TECBEAM™ joist
TECBEAM™ joist
Support wall
TECBEAM™ joist
Support wall
Fig. 3.4.3 Control Joint over Bearer/Support Wall
Hebel® PowerFloor™ panel
Possible cracking
TECBEAM™ joist
TECBEAM™ joist
Hebel® PowerFloor™ panel
TECBEAM™ joist
Steel bearer or support wall
Steel bearer or support wall
Fig. 3.4.4 Control joint Detail
Fig. 3.4.5 Control joint Detail
5mm min.
TECBEAM™ joist
5mm min.
Sealant
Hebel® PowerFloor™ panel
Sealant
Abelflex
Backing rod
TECBEAM™ joist
TECBEAM™ joist
Strongback
Timber blocking if required
24
Control joint
Wedges
Hebel® PowerFloor™ panel
Installation Detail
3.5 Construction Details
Fig. 3.5.1 Constructed detail at cantilevered TECBEAM™ joist
Stud wall
Sarking
External cladding
Hebel® PowerFloor™ panel
Blocking as required
Closure
plate
Expansion
gap to
structural
engineer’s
detail
TECBEAM™
joist
Support wall
Brick veneer wall
Fig. 3.5.2 TECSLAB™ End Support Detail
Stud wall
Steel tophat
Hebel® PowerWall™ system (Refer to
CSR Hebel Detached Houses & Low
Rise Multi-Residential External Wall
Design and Installation Guide)
Hebel® PowerFloor™ panel
Flashing
TECBEAM™ joist
Vermin proofing
Brickwork to
underside
PowerWall™
panel
Expansion
gap to
structural
engineer’s
detail
Bearer
Ant capping
Dampproof
course
Engaged pier
NOTE: The detailing of the cladding system shown below is for indicative purposes only. The project designer shall specify the construction details for the project.
25
Fig. 3.5.3 Typical Bottom Plate Fixing
for Non-bracing Partition Walls
Stud wall
Bottom plate
Hebel® PowerFloor™ panel
14-10 x 100mm MP bugle head screws as required
TECBEAM™ joist
Min. 70mm wide
Fig. 3.5.4 TECSLAB™ Strongback Detail Under Loadbearing
Walls Running Perpendicular to TECBEAM™ joists
LOAD
LOAD
LOAD
14-10 x
100mm MP
bugle head
screws as
required
Stud wall
Bottom plate
Hebel® PowerFloor™ panel
TECBEAM™ joist
Strongback
Wedges
Fig. 3.5.5 Bottom Plate Stiffening at Concentrated Load
CONCENTRATED LOAD
LOAD
14-10 x 100mm MP bugle
head screws as required
Stud wall
Bottom plate
Hebel® PowerFloor™ panel
TECBEAM™ joist
Solid blocking/trimmer beneath concentrated load
Timber packer to suit
Bearer
Offset to suit framing limitations
Fig. 3.5.6 Additional Support Detail Under Loadbearing Wall Parallel to TECBEAM™ joists
Loadbearing wall
Bottom plate
Hebel® PowerFloor™ panel
TECBEAM™ joist
Strongback
Wedges
Ensure TECBEAM™ joist is positioned
directly beneath loadbearing wall
26
Solid blocking/trimmer as required
Fig. 3.6.1 Fitted Flooring with External Loadbearing Wall
Installation Detail
3.6 Multi-Level Construction Details
5mm min.
Stud wall
Hebel® PowerFloor™ panel
TECBEAM™ joist
Brick veneer wall
Support stud wall
Fig. 3.6.2 TECSLAB™ End Support for Fitted Flooring
5mm min.
Stud wall
Hebel® PowerFloor™ panel
30mm min.
support
Solid timber beam
TECBEAM™ joist
Brick veneer wall
Fig. 3.6.3 Fitted Flooring with Internal Loadbearing Wall
5mm min.
Loadbearing stud wall
Hebel® PowerFloor™ panel
TECBEAM™ joist
5mm min.
To maintain gap, shave tongue profile
Solid timber blocking/trimming
Support stud wall
Fig. 3.6.4 Platform Flooring with Internal Loadbearing Wall
Loadbearing stud wall
Hebel® PowerFloor™ panel
TECBEAM™ joist
Solid timber blocking/trimming in between joist
and under loadbearing wall
Support stud wall
NOTE: Fitted flooring is required where the bearing stress in the Hebel PowerFloor panel, at the top of joists or the top of blocking between joists exceeds 1MPa. The
detailing of the cladding system shown below is for indicative purposes only. The project designer shall specify the construction details for the project.
27
3.7 Hold-Down/Bracing Wall Details
Fig 3.7.1 Hold-down of external bracing wall over
support wall
Fig 3.7.2 Hold-down of external bracing wall parallel
to TECBEAM™ joists
Bracing stud wall
Bracing stud wall
Wall bracing steel angle bracket
to engineer’s specifications
Hebel® PowerFloor™ panel
Brick veneer wall
Sheet bracing
10mm max. panel
overhang
Brick veneer wall
Sheet bracing
Wall bracing steel angle bracket
to engineer’s specifications
Hebel® PowerFloor™ panel
90 x 35
timber strut
10mm max. panel
overhang
TECBEAM™ joist
TECBEAM™ joist
Hold-down bolt
to engineer’s
specifications
90 x 35
timber strut
Hold-down bolt
to engineer’s
specifications
TECBEAM™ joist
Support stud wall
Support stud wall
Fig 3.7.3 Hold-down of internal bracing wall parallel to TECBEAM™ joists
Bracing stud wall
Wall bracing steel angle bracket to engineer’s specifications
Hold-down bolt to engineer’s specifications
Hebel® PowerFloor™ panel
TECBEAM™ joist
Strongback
Pair of wedges
Double TECBEAM™ joists under bracing wall if hold-down
bolts are specified (alternate detail ref. Fig. 3.7.3)
Fig. 3.7.4 Wall bracing tie-down (Alternative detail)
A) Sectional View
28
B) Longitudinal View
Installation Detail
3.8 Penetrations and Notching Details
> 80mm dia.
Fig. 3.8.1 Large Penetration and Blocking
Contact CSR Hebel® for fire
rating information, fire insulation
and acoustic insulation treatment
PVC pipe
Hebel® PowerFloor™ panel
Fire collar to project specification
Solid timber blocking required for penetrations above 80mm
TECBEAM™ joist
Fire protection to ceiling manufacturer’s specification
Ceiling system to project specification
3.9 Wet Area Detail
Fig. 3.9.1 In-situ-formed Wet Area
Foam rod as essential
bond breaker
Tiles
Edge angle
Mortar bed
Masking tape
Floor covering
In-situ membrane applied
to face of angle and floor
Hebel® PowerFloor™ panel
TECBEAM™ joist
Fig. 3.9.2 Shower Recess Detail
Shower screen
Tiles
Bond breaker
Waterproof membrane
Sand & cement tile bed
CSR fibre cement sheet
Hebel® PowerFloor™ panel
Floor waste
Backing rod
Solid timber blocking
TECBEAM™ joist
29
3.10 Balcony and Staircase Details
Fig. 3.10.1 Step-down Balcony with Cantilevered Solid Timber Beam
600mm min.
Masking tape over backing rod
Edge angle
Tiles
Hebel® Adhesive
In-situ membrane applied to
Hebel® PowerFloor™ panel and
over tape/backing rod
Window/door frame
Floor covering
TECBEAM™
Mortar bed
Hebel® PowerFloor™ panel
Foam rod as essential bond breaker
Cantilevered solid timber beam
Trimmer
Hebel® PowerFloor™ panel
Support wall
Fig. 3.10.2 In-line Balcony with Cantilivered TECBEAM™ joists
Window/door frame
Floor covering
Tiles
Hebel® PowerFloor™ panel
CSR fibre cement sheet
Cantilevered TECBEAM™ joist
Solid timber blocking
Solid timber blocking in between TECBEAM™ joists
Support wall
30
The following sections describe the type of preparation
required and any special considerations for common
floor coverings.
Underlay Installation
Carpet Installation
Carpet Installation
Installation Detail
3.11 Floor Covering Installation
Minimum medium duty underlay is to be used. No
other special requirements.
Panel Surface Preparation
Sweep the floor surface to remove debris and loose
particles. Expose all surface blemishes such as chips,
cracks, gaps, ridges or the like. Fill all unacceptable
locations with an appropriate and compatible patching
compound such as Hebel® Patch or levelling compound
as required. Ensure panels are then dry.
Carpet Smooth Edge Installation
As per carpet manufacturer’s guidelines. No other
special requirements.
Fig 3.40
Fig 3.41
Installation of Carpet Smooth Edge (Gripper) is to be in
accordance with AS/NZS 2455.1:1995.
Installation of carpet gripper prior to laying carpet
requires the use of specifically selected nails or
course threaded screws. Standard fixings supplied
with the carpet gripper are not suitable for fixing to
Hebel® PowerFloor™ panels. Carpet gripper strips
are available without factory supplied nails. For
carpet gripper installation near the panel edge, only
glue is recommended. If relying on glue only, the
carpet can not be stretched until the glue is set after
approximately 24 hours.
Fixing Type
Twist Nails
Screws
Description
Application Method
Installation Notes
51mm dome head twist nail
Coil Nail Gun (Refer to Fig 7.1)
The head of the twist nail should finish flush
with the surface of the gripper strip
Type 17 point – course
thread No. 8g x 50mm –
Countersinking screw
Makita 6834 Auto Feed
Screwdriver (Refer to Fig 7.2)
The head of the twist nail should finish flush
with the surface of the carpet gripper strip
31
3.12 Tile Installation
Panel Surface Preparation
Sweep the floor surface to remove debris and loose
particles. Expose all surface blemishes such as chips,
cracks, gaps, ridges or the like. Fill all unacceptable
locations with an appropriate and compatible patching
compound such as Hebel® Patch or levelling compound as
required. Ensure panels are then dry.
Tile Installation
As per manufacturer’s guidelines. Apply tiles to screed or
adhesive as per normal floor.
Notes: Control Joints – ensure Control Joints are installed in
tiles at the appropriate location of floor Control Joints.
Penetration – seal penetrations through waterproof
membrane.
32
Case 1: Direct Stick Adhesive
Sealer as per manufacturer’s
recommendations
Waterproof membrane as required,
for balconies and wet areas
Case 2: On Screed
Sealer as per manufacturer’s
recommendations
Panel Surface Preparation
Timber Strip Flooring
Sweep the floor surface to remove debris and loose
particles. Expose all surface blemishes such as chips,
cracks, gaps, ridges or the like. Fill all unacceptable
locations with an appropriate and compatible patching
compound such as Hebel® Patch or levelling compound
as required. Ensure panels are then dry.
Batten fix – ensuring flatness is not as critical as direct
mechanical fix. Anchor battens at the required centres
using anchors suitable for AAC, eg. Mungo MBSP1080.
Direct mechanical fix – install min. 12mm plywood
sheets to Hebel® PowerFloor™ using construction
Maxbond or equivalent and 65-75mm coarse thread
countersunk screws at max 600mm centres.
Moisture
Timber is affected by changes in environmental
conditions and it is good practice to allow the flooring
to acclimatise to the environment before installation.
If there is significant moisture in the Hebel®
PowerFloor™ (>6%) a membrane, such as min. 200
micron polyethylene sheeting, should be placed over
the top surface of the Hebel® PowerFloor™.
Installation Detail
3.13 Timber Installation
Floating Timber Floor
Underlay / backing installed as per normal for a
concrete slab.
No special requirements for floating timber flooring
installation.
33
4.1 Delivery and Storage
Unloading Panel Packs
If outside, Hebel® panels must be stored off the ground
and protected from the weather. Only single bundles
positioned on the ground can be opened. To provide a
level surface, we recommend placing temporary joists
beneath the supporting cleats.
Panel packs shall be unloaded and moved with only
approved lifting devices. Before use, the lifting devices
should be checked for the required lifting tags. Packs
should be unloaded as close as possible to the intended
installation area. This will increase work efficiency and
minimise the need for secondary lifting.
Unstrapping Packs
Ensure appropriate bracing is installed to packs prior to
removal of strapping to prevent panels from falling. Panels
can be held together with sash clamps, ratchet, straps or
Hebel® stabilising bars.
Note: Secondary handling increases the risk of panel damage.
The repair of damage sustained during lifting and moving
is the responsibility of the lifter. Where damage is excessive,
PowerClad panels must be replaced.
Storage
Refer to TECBEAM™ Installation Guidelines for delivery and
storage of TECBEAM™s.
All materials must be kept dry and preferably stored
undercover. Care should be taken to avoid sagging or
damage to ends, edges and surfaces.
All Hebel® products must be stacked on edge and properly
supported off the ground, on a level platform. Panel
bundles can be stacked two high. The project engineer
should be consulted as to the adequacy of the structure to
support the stacked bundles.
Fig. 4.1 Stacking Packs of Hebel PowerClad
Panel length
Panel
thickness
Sash clamp*
Panel
Width
Panel
Width
Temporary joists may be
required on uneven ground
34
Unstrapping bundles
without appropriate bracing.
The basic tools required to assist in the installation of
the TECSLAB™are shown in Figure 4.1. These may be
purchased through CSR Hebel® and include:
Handling, storage and responsibility
4.2 Tools and Equipment
Extra equipment will also be required and includes the
following:
•
Power drill (clutch driven)
• P
ower saw with metal or diamond tipped cutting
1. Levelling plane
blades
2.Stirrer
•
Dust extraction system
3. Panel lifters
•
Sockets and bits for screws
4. Sanding float
•
Personal Protective Equipment (PPE) such as
goggles, face mask and P1/P2 dust masks, used
when site cutting the panels
5.Trowel
Fig. 4.2 The Basic Tools and Equipment Requirements
1
2
4
3
5
35
4.3 Panel Installation
Installation Procedures
Panel Cutting
CSR Hebel® promotes and advocates a safety conscious
work place at all times. To assist builders and contractors
to maintain their safety standards, CSR Hebel® has
produced guidelines for the installation and handling
of their products. Contact CSR Hebel® for additional
information.
Hebel® PowerFloor™ Panels to be cut with a circular
saw fitted with a diamond tipped blade. The use of power
tools may cause dust, which contains respirable crystalline
silica, with the potential to cause bronchitis, silicosis and
lung cancer after repeated and prolonged exposure. When
using power or hand tools on Hebel® products, wear a
P1 or P2 respirator and eye protection. When cutting,
routing or chasing Hebel® products with power tools, use
dust extraction equipment and wear hearing protection.
Refer to CSR Hebel® MSDS sheets. For further information,
contact CSR Hebel® or visit our website:
www.hebelaustralia.com.au
Mortars & Adhesives
The Hebel® bagged mortar and adhesive should
be prepared in accordance with instructions on the
packaging.
Damaged Panels
Chipped or damaged panels are to be repaired using
Hebel® Patching Mortar. Your Hebel® supplier should be
notified immediately of any panel damage or cracking that
occurs during the handling of the panels. This damage may
result in the panel being structurally inadequate, in which
case it must be replaced.
36
Reinforcement exposed during cutting is to be coated with
a liberal application of Hebel® anti-corrosion protection
paint.
Manual Handling
CSR Hebel® recommends using a trolley or other
mechanical apparatus to move the panels around the
work site. Manual handling, where people physically
move a panel, should be kept to a minimum, with the
weight being supported by an individual kept as small
as possible. Any concerns
regarding the weight to be handled should be
discussed with the panel installing contractor.
To minimise the possibility of manual handling injuries,
CSR Hebel® suggests the following:
•
Use mechanical aids, such as trolleys, fork lifts,
cranes and levers, or team lifting to move panels.
•
Handling, storage and responsibility
4.4 Panel Handling
Keep the work place clean to reduce the risk of
slips, trips and falls which can cause injury.
• P
lan the sequence of installation to minimise panel
movements and avoid awkward lifts.
•
Keep the panels dry.
•
Train employees in good lifting techniques to
minimise the risk of injury.
Hebel® products are cement-based, which may irritate
the skin, resulting in itching and occasionally a red
rash. The wearing of gloves and suitable clothing
to reduce abrasion and irritation of the skin is
recommended when handling Hebel® products.
37
Appendix A: TECSLAB™ Material Properties
A.1 Manufacturing Tolerances
Length ± 5.0mm
Width ±1.5mm
A.5 Hebel® PowerFloor™ Thermal
Properties
• R-Value of PowerPanel with no plasterboard or other
lining = 0.48 m2. K/W (6% moisture content).
Thickness ±1.5mm
Diagonals (Max.) 5mm
Edge straightness
1.5mm
deviation (Max.)
A.2 Hebel® PowerFloor™ Physical
Properties
• Hebel® PowerFloor™ profile and nominal dimensions
are shown in Section 3.3.
• Panel reinforcement is a single layer of steel mesh with
4 longitudinal wires of 4mm diameter.
•Nominal dry density = 510 kg/m3.
A.6 Fire Hazard Indices
Hebel® products have BCA Group Number 1 and also
the following early fire hazard indices, determined in
accordance with AS1530.3:1990:
Ignitability Index 0
Spread of Flame Index 0
Heat Development Index 0
Smoke Development Index 0 - 1
• Average working density = 688 kg/m3 at 30%
moisture content.
A.7 Fire Resistance Level (FRL)
Ratings
• Average service life density = 561 kg/m3 at 10%
moisture content.
For fire performance characteristics of Hebel®
PowerFloor™, refer to Section 2.1 of this guide.
A.3 Hebel® PowerFloor™ Strength
Properties
• Characteristic Compressive Strength or AAC, f ’m= 2.8
MPa.
•Average Compressive Strength of AAC = 4.0 MPa.
• Characteristic Modulus of Rupture, f ’ut = 0.60 MPa.
A.4 Hebel® PowerFloor™ Acoustic
Properties
•Panel only with no plasterboard or other lining Rw =
36dB, Rw+Ctr = 33dB (refer to acoustic test ATF-676).
38
Following is a guide to assist in working out quantities
and costs for the required components of the Hebel®
PowerFloor™ system.
Please consult a licensed fabricator for a quote on
TECBEAMs™ for your project.
Step 1: Calculation of the Total
Floor Area
First calculate the total floor area of the building,
allowing for the panels to extend UNDER the external
wall frames.
The easiest way for this to be calculated is to determine
the overall wall length of the area being calculated,
then minus the exterior wall material and cavity
thickness. Below is a diagram of a house using the
Hebel® Low Rise External Wall System. This system gives
an overall exterior wall thickness of 185mm (90mm
stud frame, 20mm tophat batten and 75mm thick
Hebel® PowerPanel), so given the plan dimensions the
area would be worked out as follows:
• 14.000 - 0.095 - 0.095 = 13.810 m (0.095 = 75
mm Hebel® PowerPanel and 20 mm tophat)
•7.000 - 0.095 - 0.095 = 6.810 m
•Total Floor Area (TFA) = 13.810 x 6.810 = 94.0461
m2 (total area to the outside of the stud frame)
Step 2: Panel Waste
This can be calculated in two ways:
An accurate calculation by completing a detailed panel
layout and measuring the amount of waste that will
Appendix
Appendix B: Estimating TECSLAB™
be generated due to the layout of the house. Or By
applying a waste percentage to the Total Floor Area.
Generally allow an additional 5% of area. Therefore
multiply the Total Floor Area by 1.05. This calculation
gives you the total Adjusted Floor Area (TAFA).
Step 3: Material Quantities
Now that the floor area has been worked out we can
move on to working out the material quantities.
(A) Hebel® PowerFloor™ Panels:
• Area of one panel = (1.8m x 0.6m) = 1.08m2
• No. of panels = Total Adjusted Floor Area (TAFA) ÷
1.08m2
(B) Screws
•Joists @ 450cts = 8 screws required per m2 of floor
• Joists @ 600cts = 6 screws required per m2 of floor
• Total screws = (6 or 8) x Total Floor Area (TFA)
Note: Packs come in 2 sizes, 100 or 250.
Screws to be estimated based on the pack sizes.
(C) Hebel® Adhesive
• Each 20kg bag of Hebel® Adhesive glues 20m2 of
floor area.
• Total bags = Total Floor Area (TFA) ÷ 20
(D) Construction Adhesive
• Each tube of construction adhesive glues approx. 10
panels to the sub floor joists. This is 10 x 1.08m2 =
10.8m2 of floor area.
• Total tubes of adhesive = Total Floor Area (TFA) ÷
10.8
14.000 0/A
185
185
7.000 0/A
185
185
39
Appendix B: Estimating TECSLAB™ (cont.)
Client Details
Date
Client Name
Client Address
Client Phone
Client Fax
Client Email
Total Floor Area (TFA) =
Total Adjusted Floor Area
(TAFA) =
Item
m2
1.05 x TFA =
m2
Quantity
Panels
TFA ÷ 1.08 =
Screws
(Joists @ 600)
OR
(Joist @ 450)
TFA x 6 =
OR
TFA x 8 =
Cost / Unit
Total Cost
$
(250)
$
(100)
$
Hebel Adhesive
TFA ÷ 20 =
$
Construction Adhesive
TFA ÷ 10.8 =
$
TOTAL
40
$
Appendix
Design notes:
41
Appendix C: PowerFloor System Description
Code
System Description
TECSLAB™ 1600
Houses, Low Rise and Commercial Floor Carpet Ground Floor Enclosed
TECSLAB™ 1601
Houses, Low Rise and Commercial Floor Carpet Ground Floor Unenclosed
TECSLAB™ 1602
Houses, Low Rise and Commercial Floor Carpet 2nd Storey Gyprock Ceiling (CSR 821)
TECSLAB™ 1603
Houses, Low Rise and Commercial Floor Carpet 2nd Storey Gyprock Ceiling (CSR 826)
TECSLAB™ 1604
Houses, Low Rise and Commercial Floor Carpet 2nd Storey Gyprock Ceiling (CSR 827)
TECSLAB™ 1615
Houses, Low Rise and Commercial Floor Vinyl Ground Floor Enclosed
TECSLAB™ 1616
Houses, Low Rise and Commercial Floor Vinyl Ground Floor Unenclosed
TECSLAB™ 1617
Houses, Low Rise and Commercial Floor Vinyl 2nd Storey Gyprock Ceiling (CSR 821)
TECSLAB™ 1618
Houses, Low Rise and Commercial Floor Vinyl 2nd Storey Gyprock Ceiling (CSR 826)
TECSLAB™ 1619
Houses, Low Rise and Commercial Floor Vinyl 2nd Storey Gyprock Ceiling (CSR 827)
TECSLAB™ 1620
Houses, Low Rise and Commercial Floor Timber Battens Ground Floor Enclosed
TECSLAB™ 1621
Houses, Low Rise and Commercial Floor Timber Battens Ground Floor Unenclosed
TECSLAB™ 1622
Houses, Low Rise and Commercial Floor Timber Battens 2nd Storey Gyprock Ceiling (CSR 821)
TECSLAB™ 1623
Houses, Low Rise and Commercial Floor Timber Battens 2nd Storey Gyprock Ceiling (CSR 826)
TECSLAB™ 1624
Houses, Low Rise and Commercial Floor Timber Battens 2nd Storey Gyprock Ceiling (CSR 827)
TECSLAB™ 1625
Houses, Low Rise and Commercial Floor Timber Floating Ground Floor Enclosed
TECSLAB™ 1626
Houses, Low Rise and Commercial Floor Timber Floating Ground Floor Unenclosed
TECSLAB™ 1627
Houses, Low Rise and Commercial Floor Timber Floating 2nd Storey Gyprock Ceiling (CSR 821)
TECSLAB™ 1628
Houses, Low Rise and Commercial Floor Timber Floating 2nd Storey Gyprock Ceiling (CSR 826)
TECSLAB™ 1629
Houses, Low Rise and Commercial Floor Timber Floating 2nd Storey Gyprock Ceiling (CSR 827)
TECSLAB™ 1605
Houses, Low Rise and Commercial Floor Tiles Ground Floor Enclosed
TECSLAB™ 1606
Houses, Low Rise and Commercial Floor Tiles Ground Floor Unenclosed
TECSLAB™ 1607
Houses, Low Rise and Commercial Floor Tiles 2nd Storey Gyprock Ceiling (CSR 821)
TECSLAB™ 1608
Houses, Low Rise and Commercial Floor Tiles 2nd Storey Gyprock Ceiling (CSR 826)
TECSLAB™ 1609
Houses, Low Rise and Commercial Floor Tiles 2nd Storey Gyprock Ceiling (CSR 827)
TECSLAB™ 1610
Houses, Low Rise and Commercial Floor Tiles on Topping Slab Ground Floor Enclosed
TECSLAB™ 1611
Houses, Low Rise and Commercial Floor Tiles on Topping Slab Ground Floor Unenclosed
TECSLAB™ 1612
Houses, Low Rise and Commercial Floor Tiles on Topping Slab 2nd Storey Gyprock Ceiling (CSR 821)
TECSLAB™ 1613
Houses, Low Rise and Commercial Floor Tiles on Topping Slab 2nd Storey Gyprock Ceiling (CSR 826)
TECSLAB™ 1614
Houses, Low Rise and Commercial Floor Tiles on Topping Slab 2nd Storey Gyprock Ceiling (CSR 827)
42
SLAB
The better way to build
TECSLAB™ is a quality building product, and is backed
by CSR Building Products Limited and TECBEAM™
Australasia Pty Ltd. Further details on engineering and
building with the TECSLAB™ system is available on our
website www.tecslab.com.au
CSR Hebel®
Tel 1300 369 448
[email protected]
www.hebelaustralia.com.au
TECBEAM™
Tel +613 9696 8877
[email protected]
www.tecbeam.com.au
Health & Safety
Other
Information on any known health risks of our products and how to
handle them safely is on their packaging and/or the documentation
accompanying them. Additional information is listed in the Material
Safety Data Sheet (MSDS).
The design of a wall, floor or fence system requires the services
of professional consultants. This Design Guide has been prepared
as a source of information to provide general guidance to those
consultants – and in no way replaces the services of the professional
consultant and relevant engineers designing the project.
To obtain a copy of a MSDS, telephone 1800 807 668 or download
from www.hebelaustralia.com.au. Contractors are required by law to
perform their own risk assessments before undertaking work. Hebel
has sample Safe Work Method Statements (SWMS) to assist in this.
To obtain a sample SWMS, refer also to the above sources.
Performance & Certification
Hebel® products are manufactured in Australia by CSR Building
Products.
A.B.N. 55 008 631 356. It is a manufacturer and supplier of
Hebel Autoclaved Aerated Concrete (AAC) products. Because it is
a manufacturer and supplier only, CSR does not employ people
qualified as Accredited or Principal Certifiers. CSR is therefore unable
to provide Construction Compliance Certificates or Statements of
Compliance. CSR conducts appropriate testing of its products and
systems to determine performance levels. These include structural,
fire and acoustic tests. Testing is conducted and certified by
appropriate specialists in these fields. When using Hebel products
and systems in specific projects, such specialists should be consulted
to ensure compliance with the Building Code of Australia and
relevant Australian Standards.
Guarantee
Hebel® guarantees the products manufactured by itself and the
systems described in Hebel literature for 7 years, subject to the terms
and conditions of the Hebel®Guarantee which can be inspected
in the Hebel website at hebelaustralia.com.au. Hebel does not
however guarantee the components, products or services, such
as installation, supplied by others. Hebel® recommends that only
products, components and systems recommended by it be used.
No liability can therefore be accepted by CSR or other parties for
the use of this Design Guide. Hebel products and systems undergo
constant research and development to integrate new technology
and reflect ongoing performance enhancement.
Hebel systems are also constantly reviewed so as to reflect any
changes in legislative building requirements and or general
developments in common building practice. Due to our commitment
to continual development and improving our building systems.
We advise that all users of this manual: HEB1279 August 2011
should regularly check that this manual is current, and they are
applying our latest design information.
The latest editions of our Design Guides and supplementary
diagrams and technical data are always available on our website:
www.hebelaustralia.com.au
Disclaimer
The information presented herein is supplied in good faith and to
the best of our knowledge was accurate at the time of preparation.
The provision of this information should not be construed as a
recommendation to use any of our products in violation of any
patent rights or in breach of any statute or regulation. Users are
advised to make their own determination as to the suitability
of this information in relation to their particular purpose or
specific circumstances. Since the information contained in this
document may be applied under conditions beyond our control, no
responsibility can be accepted by Hebel®‚ or its staff for any loss or
damage caused by any person acting or refraining from action as a
result of misuse of this information.
Available from:
43
March 2012
48–50 Hallam South Road
Hallam VIC 3803
Tel
Fax
1800 333 162
03 9796 3449
[email protected]
SLAB
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